System and method of building construction

ABSTRACT

A method of building construction includes mounting a rigid insulation sheet over an outer vertical surface of a concrete wall and applying a flexible membrane sheet over at least an above-grade portion of the rigid insulation sheet.

FIELD OF THE INVENTION

This invention relates to the field of buildings, and more specifically to a system and method of building construction.

BACKGROUND

When constructing a building, such as a single family dwelling, insulating and sealing the basement can lead to problems. For instance, when insulation for a living space is on the inside of a basement wall, mold can be a problem because of condensation between the insulation and the wall.

Some builders have a placed a spray-applied membrane directly to an outer surface of the wall to seal the wall and then apply a sheet of rigid insulation over the membrane. However, this system does not allow a wall to breathe to expel moisture.

SUMMARY

In one aspect, the present system includes a method of building construction including mounting a rigid insulation sheet over an outer vertical surface of a concrete wall and applying a flexible membrane sheet over at least an above-grade portion of the rigid insulation sheet.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a partial cut-away perspective view of a portion of a building constructed according to one embodiment.

FIG. 2 shows a side cross-section view of a wall of the building of FIG. 1.

FIG. 3 shows a perspective view of a portion of the wall of FIG. 1.

FIG. 4 shows a perspective view of a portion of a building constructed according to one embodiment.

FIG. 5 shows a perspective view of a portion of the wall of FIG. 4.

FIG. 6 shows a flexible sheet, in accordance with one embodiment.

FIG. 7 shows a perspective view of a portion of the wall of FIG. 4.

FIG. 8 shows a perspective view of a portion of the wall of FIG. 4.

DETAILED DESCRIPTION

In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the present invention. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.

FIG. 1 shows a partial cut-away perspective view of a portion of a building 100 constructed according to one embodiment of the present system. Building 100 can include a single family or a multi-family dwelling, for example. In this example, building 100 includes a wooden frame structure 110 supported by a lower foundation concrete wall 120. In various examples, concrete wall 120 can include a concrete block wall, a concrete slab wall, or a pre-formed concrete wall. Concrete wall 120 includes a portion that will be at least partially below grade G and a portion above the grade G. The inside of concrete wall 120 can be an inside wall of a basement or garage, for example.

In one embodiment, building 100 is constructed so as to allow moisture to breathe through wall 120 and not condense inside the house. For example, a first layer over wall 120 includes a drainage sheet, such as a dimpled sheet 130. Dimpled sheet 130 includes a plurality of raised hemispherical areas that provide for small spaces between wall 120 and sheet 130. This helps condensing moisture drain down the outside of the wall. In one example, sheets 130 can be DELTA brand dimpled sheets. Over sheet 130 is a rigid insulation sheet 140. Insulation sheets 140 have a portion above grade G and a portion below the grade and extend up to the top of wall 120. Over the insulation sheet 140 is a flexible membrane sheet 150 which extends up to and over the top surface of wall 120. As used herein, “over” and “cover” mean that the item is over, but not necessarily adjacent to another item. Thus, “over” and “cover” are not limited to mean that another item cannot be between a pair of items when one item is over another or covers another item.

As can be seen on the right hand side of FIG. 1, after the backfill has been filled in, flexible sheet 150 is the only part of the wall construction that is exposed. Sheet 150 protects the insulation sheets 140 underneath the sheet 150 and provides an aesthetic finish. Furthermore, sheets 150 are easily patched if a hole or rip develops. As will be discussed below, sheets 150 can be made of a TPO (thermoplastic polyolefin) membrane material that is easily heat-welded, and a patch can be formed and placed over and tightly welded to the surrounding material providing a watertight seal.

FIG. 2 shows a side cross-section view of wall 120, constructed in accordance with one embodiment. In this example, dimpled sheet 130 is located adjacent the concrete wall. As noted, dimpled sheet 130 provides an area where condensed moisture can drip down the outside of the wall. In some embodiments, dimpled sheet 130 is omitted.

Adjacent to and covering over the dimpled sheet 130 is rigid insulation sheet 140. Insulation sheet 140 can be a rigid foam insulation sheet sized 4′×8′, such as a 1-inch thick or greater insulation. Some embodiments use up to a 2¼″ insulation or greater. Rigid insulation sheet 140 can have an R value of about R-4 to R-16. In some embodiments, a top edge 232 of the rigid insulation sheet is beveled, having an angle of about 45 degrees, for example. In other examples, the angle can vary from about 25 to 75 degrees. As will be explained below, the beveled edge allows the flexible sheet 150 to be more easily mounted over the insulation.

Exposed on the outer surface of the wall is flexible membrane sheet 150 which covers insulation sheet 140 over at least an above-grade portion of the insulation sheet. In some embodiments, the flexible sheet 150 can extend over the entire surface of the insulation. In some examples, the flexible sheet includes a TPO membrane sheet. For example, a GENFLEX brand TPO sheet having a thickness of between 36-60 mils can be used. Such a product typically comes in an 18″ to 8′ roll. Individual pieces can be cut on the roll and attached to the building as described herein. In some examples, the flexible membrane can include a rubber sheet. In some embodiments, the sheet 150 includes a watertight sheet. In some examples, the flexible sheet includes a single-ply membrane. The flexible membrane sheet 150 can be chosen to be watertight, UV-resistant, durable, reinforced, and aesthetic. Different colors can be used as desired. The sheet covers over the insulation to provide a watertight, aesthetic finish and protect the insulation from damage.

The entire wall system of FIG. 2 provides for optimal construction. For example, by putting the insulation sheets 140 on the outside of the wall 120, condensation happens on the outside of the wall instead of the inside. This prevents mold and other water problems in the house. Furthermore, the drainage sheets 130 allow the moisture to run down the wall to drainage tiles, for example. The flexible sheet 150 protects the insulation and provides a nice finished look to the house. In some embodiments, dimpled sheet and insulation can be omitted and the flexible sheet 150 is directly over the concrete wall 120.

In one embodiment, to construct the building, the outer vertical surface of the wall 120 is covered with a plurality of dimpled sheets 130. The dimpled sheets can be mounted using nails, screws, or adhesive. Then the rigid insulation sheets 140 are placed over the dimpled sheets. Again, nails, screws, adhesive, or other fastening methods can be used to mount the rigid insulation sheets to the wall. Then the flexible sheet 150 is applied over the insulation.

One method of applying the flexible sheet 150 includes first fastening the sheet along a sill plate 240 using bolts 242, staples, nails, or other fasteners. Flexible membrane sheet 150 is then pulled down tautly over the insulation sheet 140. As noted above, providing a beveled edge on the top of the insulation sheet can help provide a more taut application. Nails 250, rivets, screws, or adhesive can then be used to hold the flexible sheet 150 in place over the insulation sheet 140. The sheet 150 can extend at least to the grade level G of the building (See FIG. 1). Some examples extend flexible sheet 150 down about a foot or two below grade. In some example, sheet 150 can cover the entire insulation sheet 140. After the backfill is added the backfill helps hold the sheet 150 tautly in place.

FIG. 3 shows a perspective view of a wall constructed according to one embodiment. A second flexible sheet 150B is put on like the first sheet 150, as described above, with a section of sheet 150B overlapping a section of sheet 150. When the second sheet 150B is on, the two sheets are heat-welded together at the overlapping section along seam 310, using a heat gun, for example. Other examples use an adhesive instead of heat welding. The seam 310 is watertight and when all the sheets 150 for the building are on they form a completely sealed covering, providing an aesthetic, watertight, and protective covering over the insulation sheets 140.

FIG. 4 shows a perspective view of a portion of a building constructed according to one embodiment. In this example, a transition wall 410 includes a series of different height sections with one or more flexible sheets 450A, 450B, 450C, and 450D on each level. In this example, a lower section of sheet 450B is cut-out and forms a seam 403 with sheet 450A.

FIG. 5 shows a perspective view of a portion of the wall 410. In this example, the flexible sheet 450C is wrapped partially around a side of the wall and attached using rivets 502. The sheet 150 is attached at the top of the wall by a bolt 540. Referring to FIG. 6, sheet 450C includes a cut 452 in an upper corner. Thus, when the sheet is placed on the wall, a first side 454 can be laid down and the other side 456 is laid over section 454. A seam 453 is then heat welded between sections 454 and 456. In one example, a patch 460 can be placed over and heat welded to at least a portion of the seam 453 to further seal the wall.

FIG. 7 shows a perspective view of a portion of wall 410. In this example sheets 450C and 450D meet at a corner of the wall and the overlapping sections of the sheets are heat welded together. Again a patch 702 can be welded to both sheets to cover any section without adequate overlap.

FIG. 8 shows a perspective view of a portion of a wall. This example shows that a sheet 450A can be at least partially wrapped around a corner 450 of the wall and attached using rivets 802 or other means to the inside of the wall. The sheet can be cut to allow it to fold over the top corner edge 806 of the wall. The cut section is then heat welded together at seam 804.

The present system can be used to cover a wall or the outer insulation of a wall of almost any shape. The flexible membrane sheets discussed herein are flexible enough to be cut and folded into almost any configuration allowing them to then be attached to each by heat sealing, for example, and providing a sealed outer covering to protect the insulation and provide an aesthetic finish.

It is understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. 

1. A method comprising: mounting a rigid insulation sheet over an outer vertical surface of a concrete wall; and applying a flexible membrane sheet over at least an above-grade portion of the rigid insulation sheet.
 2. The method of claim 1, wherein applying the flexible membrane sheet includes applying a TPO sheet.
 3. The method of claim 1, wherein applying the flexible membrane sheet includes applying a rubber sheet.
 4. The method of claim 1, wherein applying the flexible membrane sheet includes applying a watertight sheet.
 5. The method of claim 1, wherein mounting the rigid insulation sheet includes mounting a rigid insulation sheet having a thickness of at least 1 inch.
 6. The method of claim 1, wherein mounting the rigid insulation sheet includes mounting a rigid insulation sheet having a beveled upper edge.
 7. The method of claim 1, further including mounting a dimpled sheet between the concrete wall and the rigid insulation sheet.
 8. A method comprising: mounting a plurality of dimpled sheets to an outer vertical surface of a concrete foundation wall that is at least partially below-grade; mounting a plurality of rigid insulation sheets over the plurality of dimpled sheets and at least up to a top of the concrete foundation wall; and applying a plurality of flexible membrane sheets over at least an above-grade portion of the rigid insulation sheets and up to and over the top of the concrete foundation wall.
 9. The method of claim 8, wherein applying the plurality of membrane sheets includes heat welding the sheets to each other.
 10. The method of claim 8, wherein applying the flexible membrane sheets includes applying a TPO sheet.
 11. The method of claim 8, wherein applying the flexible membrane sheets includes applying a rubber sheet.
 12. The method of claim 8, wherein applying a flexible membrane sheets includes applying a watertight sheet.
 13. A building construction system comprising: a concrete wall at least partially below grade and partially above grade and having an outer vertical surface; and a flexible membrane sheet over at least the above grade portion of the outer vertical surface of the concrete wall.
 14. The building construction system of claim 13 wherein the flexible membrane sheet includes a TPO sheet.
 15. The building construction system of claim 13, wherein the flexible membrane sheet includes a rubber sheet.
 16. The building construction system of claim 13, wherein the flexible membrane sheet includes watertight sheet.
 17. The building construction system of claim 13, including a rigid insulation sheet between the concrete wall and the flexible membrane sheet.
 18. The building construction system of claim 17, further including a dimpled sheet between the concrete wall and the rigid insulation sheet.
 19. A method comprising applying a flexible membrane sheet over at least an above-grade portion of an outer vertical surface of a concrete wall of a building. 